A leading pharmaceutical company recently implemented the Elios 2 drone for tank inspections as part of its Riboflavin testing process. The results were impressive, showcasing significant improvements in efficiency, safety, and cost savings.

Key Benefits at a Glance

About the Process

Pharmaceutical companies rely on large stainless steel tanks for production. These tanks must be thoroughly cleaned after each batch to maintain hygiene standards. One common method used to verify cleaning effectiveness is the Riboflavin test.

This involves spraying a fluorescent substance called Riboflavin inside the tank using a long rod. After it's applied, the tank is cleaned, and UV lights are used to check if any residue remains. If so, the cleaning process is repeated until no trace is found.

The process requires workers to enter the tank twice—once to ensure even coverage and again to confirm that all Riboflavin has been removed. This not only takes time but also poses safety risks due to confined spaces and potential chemical exposure.

Company Needs

A major pharmaceutical plant in Austria had multiple large tanks that needed regular Riboflavin testing. The company wanted to explore new technologies to speed up the process, reduce downtime, and improve worker safety by eliminating manual entry into the tanks.

They were particularly interested in conducting both verification steps remotely, without requiring personnel to enter the vessels.

How AEROVISION Drone Support Gmbh Helped

AEROVISION Drone Support GmbH, an Austrian-based drone inspection service, proposed using the Elios 2 for the next round of tests. The Elios 2 is designed to fly in tight spaces and capture high-quality visual data, making it ideal for this application.

Markus Rockenschaub from AEROVISION tested the drone during the plant’s next round of Riboflavin testing, replacing manual inspections with drone-assisted ones.

Results Achieved

Rockenschaub successfully completed inspections on five tanks in one day using the Elios 2. He live-streamed the footage to a large screen, allowing the team to monitor the entire process in real-time.

The two main steps were performed as follows:

1. After spraying the Riboflavin, the Elios 2 was flown inside to check for full coverage.
2. After cleaning, the drone was used again to confirm that no residue remained.

The results were clear and accurate, and the company saw immediate benefits:

• Cost Savings: 60,000 Euros saved through reduced downtime.
• Time Saved: Inspection time dropped from ten hours to just four.
• Improved Safety: No personnel entered the tanks, reducing risk.
• Fewer Workers Needed: From five to three people per test.

In some cases, the drone detected residual Riboflavin, prompting additional cleaning. While this is normal, it would have taken longer if done manually, increasing downtime.

Looking Ahead

Based on the success of the trial, the pharmaceutical company is planning to use the Elios 2 more frequently for future inspections. With more tanks being added in the coming months, they want to streamline the testing process using drones.

The company is also exploring the possibility of attaching UV lights to the Elios 2, which could enhance visibility of the fluorescent Riboflavin and make inspections even more effective.

This case highlights how innovative technology like the Elios 2 can transform traditional processes, offering safer, faster, and more cost-effective solutions in industrial settings.

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